Gas turbine compressor water wash control of drain water purge and sensing of rinse and wash completion

ABSTRACT

A purge drain valve including a spool spliced in a fluid line includes a control valve and an actuator coupled to the control valve for regulating fluid flow. During a washing operation, fluid flows between a supply end and a delivery end of the spool, and during a purging operation, the control valve diverts fluid entering the supply end from the delivery end towards a drain leg. A washing system includes a fluid supply coupled to an input of a wash delivery system and a delivery line coupled to an output of the wash delivery system. The purge drain may be spliced into the delivery line to permit fluid to reach a wash apparatus during a washing operation and to prevent fluid from reaching the wash apparatus during a purging operation. A rinse cycle sensor apparatus may be employed to indicate to an operator if a washing operation is complete based upon a conductivity of fluid exiting from a device being washed.

REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. application Ser. No.11/869,404, filed Oct. 9, 2007, which claims benefit of U.S. ProvisionalPatent Application Nos. 60/852,041, filed Oct. 16, 2006, and 60/861,401,filed Nov. 28, 2006, the entire contents of which are herebyincorporated by reference.

TECHNICAL FIELD

The present invention relates to on-line and off-line wash processes ofa gas turbine compressor. More specifically, an apparatus prevents waterfrom reaching compressor blades during a wash manifold purge operationfollowing the on-line wash process, and a second apparatus indicates arinse completion during an off-line wash process.

BACKGROUND

An on-line wash process for a gas turbine compressor is performed toclean the compressor of contaminates that may become attached tocompressor blades during operation and that may drastically reduceefficiency of the compressor. After the on-line wash process of the gasturbine compressor, a purge may be performed on nozzle supply lines thatmay be utilized to supply wash to the compressor. The purge may reduceor eliminate de-mineralized or de-ionized water that may be collected inthe nozzle supply lines during the on-line wash process. During thepurge, low pressure water may exit the nozzles of the cleaning apparatusand flow into the compressor, impinging compressor blades. As the streamof water continues to impact the rotating compressor blades over amultitude of washes, it may form a stress riser from erosion on thesurface of the blade. This erosion of the blade may typically lead toincreased maintenance costs and/or a potentially catastrophic failure inthe compressor. Thus, an apparatus is needed to prevent low pressurewater from reaching the nozzles.

An off-line wash process for a gas turbine compressor is performed tomore effectively clean the compressor of the attached contaminates.During the off-line wash process, detergent is added to water forremoval of the contaminates that water alone cannot achieve.Additionally, an extensive amount of de-mineralized or de-ionized wateris used to ensure the effectiveness of the wash and the optimization ofperformance recovery. De-mineralized and de-ionized water is expensiveto process and often in limited supply at many sites. Operators areconsequently forced to compromise between using more water thannecessary to thoroughly complete a rinse or using too little water andleaving behind detergent residue, which may absorb into the blades andreduce performance of the compressor. In both cases, expense and wasteis incurred. Thus, an apparatus is needed to analyze a termination timefor the off-line wash process, indicating that the detergent has beenfully rinsed from the compressor and that the rinsing of the off-linewash process is complete.

SUMMARY

A washing and rinsing system for use in an on-line wash process of a gasturbine compressor operates to eliminate a stream of low pressure waterinto the compressor. A wash delivery system delivers fluid through adelivery line to a wash apparatus during the on-line wash process. Whena purge operation is being performed to eliminate de-mineralized and/orde-ionized water collected in the delivery lines of the system, a purgedrain valve is actuated. The drain valve may be mounted at a junction ofthe delivery line and the wash apparatus. The drain valve includes anactuator for simultaneous draining of the collected water from thedelivery line and the wash apparatus.

A second apparatus is used during an off-line wash process to sensecompletion of a rinse cycle of a gas turbine compressor. The apparatusmay be placed in the discharge drain line of the gas turbine compressor.A sensor takes readings of a wash rinse being discharged, and thereadings are provided to a computing system by a transmitter attached tothe sensor. Preset conditions specify conditions when the rinse cyclemay be terminated and may indicate an amount of detergent and/orcontaminates in the wash rinse.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 a is a diagram illustrating details of an exemplary purge drainapparatus.

FIG. 1 b is a diagram illustrating details of another exemplary purgedrain apparatus.

FIG. 2 is a block diagram of an exemplary washing and rinsing system.

FIG. 3 is an exemplary illustration of a rinse cycle sensor apparatus.

FIG. 4 is a cross-sectional view of an exemplary gas turbine inlet.

DETAILED DESCRIPTION

The present disclosure relates to a system, method, and apparatus forsensing completion of a fluid washing and/or rinsing operation and forcontrolling fluid flow during a fluid purging operation. To that end,the present disclosure describes a novel “feedback loop” for use in awashing and/or rinsing system. This feedback loop is configured toindicate when washing and/or rinsing operations of such a system havebeen completed. With such an indication, an operator of thewashing/rinsing system is able minimize the amounts of fluids usedduring such operations, resulting in cost savings and in reducedwash/rinse times. In another aspect, the present disclosure describes anovel purge drain valve for controlling the flow of fluids during apurging operation. As further discussed below, the feedback loop andpurge drain valve combine to provide a novel system for controlling andoptimizing the flow of fluids during both a washing/rinsing operationand during a fluid purging operation.

Referring now to FIG. 1 a, an exemplary purge drain valve 100 inaccordance with the present disclosure is illustrated. This purge drainvalve 100 comprises a spool 105 having a supply end 106, a delivery end107, and a drain leg 108. Coupled to the supply and delivery ends 106and 107 are flanges 110 for use in splicing the purge drain valve 100into a fluid line, thereby defining a supply side and a delivery side ofthe fluid line (not shown), respectively. Although raised face (RF)flanges are shown in this illustration, it should be understood that anyadequate flange known in the art may be utilized in accordance with thepresent disclosure.

Also included as part of the exemplary purge drain valve 100 is acontrol valve 115 for regulating and directing fluid flow as desired.Any suitable control valve 115 known in the art may be utilized,although a full port ball-type valve is preferred as it may be effectivein reducing any pressure drops experienced within the control valve 115itself during operation. Since the exemplary purge drain valve 100 is atwo-way device, the control valve 115 is shown coupled to the drain leg108 of the purge drain valve 100. Alternatively, if the purge drainvalve 100 were configured as a three-way valve 100′, as illustrated inFIG. 1 b, the control valve 115′ could be disposed within the spool 105′between the supply and delivery ends 106′ and 107′ forregulating/diverting the flow of fluid.

Coupled to the control valve 115 of the purge drain valve 100 is a valveactuator 120 for opening and closing the control valve 115 as desired.The valve actuator 120 may be operated by any means known in the artsuch as, for example, electrically, pneumatically, or manually operated.

The end of the drain leg 108 may configured for coupling to a drainfluid capturing system for capturing any fluid diverted due to actuationof the control valve 115.

In operation, the exemplary purge drain valves 100 illustrated in FIG. 1a may be utilized in a washing and rinsing system, which system is usedfor cleaning large industrial equipment, such as large gas turbinecompressors, for example. In such a system, the purge drain valve 100may be spliced into a system fluid line that delivers fluid from a fluidsource to a fluid delivery mechanism. During the system'swashing/rinsing operation, the control valve 115 is completely opened soas to allow fluid to freely flow from the fluid source to the fluiddelivery system. Once the washing/rinsing operation is complete,however, fluid may remain in the fluid line, thereby requiring a purgingoperation to rid the fluid line of any such fluid.

Simply purging the fluid line by forcing air through it, however, mayactually cause damage to the equipment being washed. To illustrate, ifthe washing/rinsing system described above were used to wash and rinse agas turbine compressor, de-mineralized or de-ionized water would remainin the system's fluid lines once the washing/rinsing operations werecompleted. If pressurized air were used to purge the fluid line, thecontents of the fluid line would simply be forced to impinge onto theturbine compressor's blades, which could result in blade erosion. Thenovel purge drain valve 100 of the present disclosure avoids such aproblem by safely preventing purged fluid from reaching any equipmentbeing washed by the washing/rinsing system.

Once the system's washing/rinsing operations are completed, and prior toinitiating the system's purging mechanism, the valve actuator 120actuates the control valve 115, thereby shutting off or diverting thepath of the fluid to the compressor. Once the control valve 115 isactuated, air may be safely injected into the fluid line. The air forcesany remaining fluid in the line to flow through the spool 105 and out ofthe drain leg 108, thereby preventing the purged fluid from reaching thecompressor.

Referring now to FIG. 2, an exemplary washing and rinsing system 200(hereinafter, the “wash system 200”) is shown comprising the exemplarypurge drain valve 100 described above. As indicated above, the washsystem 200 may be utilized for cleaning large, industrial equipmentincluding, without limit, gas turbine compressors.

Included in the exemplary wash system 200 is a wash delivery system 205for delivering fluids such as water, wash solvents, purge air, and/orother substances from a fluid supply line 225 to a fluid delivery line210. The wash delivery system 205 may include one or more containers forstoring fluids for use in washing/rinsing operations. Depending on theparticular application, the wash delivery system 205 may be configuredto condition or process any fluids being stored therein in anticipationof a washing/rinsing operation.

A control input communication link 220 is coupled to the wash deliverysystem 205 for delivering control communications signals to the washdelivery system 205 related to the delivery of fluids. These controlsignals may be generated from a remote controller (not shown), such as,for example, an operator, a computing device, and/or a plant controller.

Also coupled to an input of the wash delivery system 205 is a fluidsupply line 225 for delivering washing/rinsing fluid from a fluid supplysource (not shown) to the wash delivery system 205. The fluid supplyline includes a supply valve (not shown) for regulating the flow offluid into the wash delivery system 205.

Powering the wash delivery system 205 is a power supply 230.

Coupled to an output of the wash delivery system 205 is a fluid deliveryline 210 for delivering fluids from the wash delivery system 205 to awash apparatus 215. The wash apparatus 215 may be any suitable apparatusknown in the art for use in washing large, industrial equipment such asa water wash manifold, a nozzle assembly, a supply pump, reservoirtanks, and/or a combination thereof.

Spliced into the fluid delivery line 210, between the wash deliverysystem 205 and the wash apparatus 215, is a novel purge drain valve 100.The purge drain valve 100, as described above, is used to regulate theflow of fluids through the fluid delivery line 210 during washing andrinsing operations and during purging operations. The purge drain valve100 comprises a control valve 115 which is actuated via a valve actuator120. Depending on whether the purge drain valve 100 is a two-way orthree way valve, the control valve may be coupled to a drain leg portionof the purge drain valve 100 or the control valve 115 may be within thespool portion of the purge drain valve 100.

A drain communication link 240 is coupled between the wash deliverysystem 205 and the purge drain valve 100 for transmitting controlsignals to control the actuation of the purge drain valve 100. Thesecontrol signals are automatically generated via the wash delivery system205 once a purging operation is initiated. Alternatively, the controlsignals may be generated external to the system 200 and transmitted fromthe control input communication link 220, through the wash deliverysystem 205, and through the drain communication link 240 to the drainvalve 100.

Optionally, a drain collector 245 may be positioned beneath the purgedrain valve 100 and/or coupled to the drain leg of the purge drain valve100 for transfer to a controlled drain or for collecting purged fluidsexiting the system 200.

In operation, the control input communication link 220 transmits controlsignals to the wash delivery system 205 to initiate a washing and/orrinsing process. These control signals may be generated from a remotecontroller (not shown), such as, for example, an operator, a computingdevice, and/or a plant controller. In response to the control signals,the wash delivery system 205 opens the supply valve (not shown) coupledto the fluid supply line 225, thereby enabling washing/rinsing fluid toenter the wash delivery system 205. The wash delivery system 205 thendispenses the fluid through the fluid delivery line 210 accordingly.Optionally, before dispensing of the fluid, the wash delivery system 205may condition or otherwise process the fluid according to the particularapplication.

Since the system 200 is in a “washing” or “rinsing” mode, controlsignals transmitted via the drain communication link 240 instruct thepurge drain valve 100 to remain open, thereby allowing the fluid tofreely flow between the wash delivery system 205 and the wash apparatus215. The control signals for regulating the purge drain valve 100 mayoriginate from the wash delivery system 205 as provided from a remotecontroller.

Once the washing and/or rinsing operation is completed, the controlinput communication link 220 transmits a control signal to the washdelivery system 205 to cease dispensing wash fluid to the wash apparatus215. The control signal may originate automatically or from a remotecontroller. In response, the water wash delivery system 205 closes thesupply valve coupled to the fluid supply line 225, thereby preventingany further fluid from entering the wash delivery system 205. The draincommunication link 240 then transmits control signals to the purge drainvalve 100 for initiating a purge operation. In response, the purge drainvalve's actuator 120 actuates the control valve 115 to divert the flowof fluids away from the wash apparatus 215 and down through the drainvalve's drain leg 108. Alternatively, the purge drain valve 100 may beactuated pneumatically or manually, depending on the particularimplementation. Once the purge drain valve 100 is actuated, the washdelivery system 205 purges the delivery line 210 of any remaining fluidsby delivering pressurized air through the fluid delivery line 210.

Any fluids that remain in the fluid delivery line 210 between the washdelivery system 205 and the purge drain valve 100 will be forced throughthe drain valve 100 and out through the valve's drain leg 108 to a draincollector 245. Fluids remaining in the wash apparatus 215 and in thefluid delivery line 210 between the purge drain valve 100 and the washapparatus 215 are initially driven through a nozzle tip, forapproximately 15 to 20 seconds, for example, but will rapidly allow airpassage to the nozzle and will be allowed to drain, free following thestop command for the purge air flow. At the purge drain valve 100, thefluids draining from the wash apparatus are diverted to and collected bythe drain collector 245.

In an exemplary implementation wherein the system 200 of FIG. 2 isutilized to wash a gas turbine compressor, the wash apparatus 215 may beinserted within an inlet of the compressor to allow fluids to reach andclean the inlet. Once the washing procedure is complete, the purge drainvalve 100 may be actuated and a purging operation may be initiated. Asthe purge drain valve 100 during the purging operation prevents fluidsfrom entering the inlet of the compressor, turbine blade erosion andother blade damage may be significantly reduced.

With reference to FIG. 3, components 310, 320 of an exemplary rinsecycle sensor apparatus 300 is illustrated. The exemplary rinse cycleapparatus 300 may be utilized during a washing and/or rinsing operationsas a “feedback loop” for indicating to an operator when the washingand/or rinsing operations have been completed. With such an indication,an operator of the washing/rinsing system is able to minimize theamounts of fluids used during such operations, resulting in cost savingsand in reduced wash/rinse times

In an exemplary embodiment, the components 310, 320 of the sensorapparatus 300 may be implemented in the exemplary system 200 of FIG. 2,although the cycle sensor apparatus 300 is not limited to such systems.Indeed, as further explained below with reference to FIG. 4, the sensorapparatus 300 may be utilized during an off-line wash/rinse operation.

The exemplary rinse cycle sensor apparatus 300 comprises a conductivitysensor 310 and a transmitter 320. The conductivity sensor 310, which maybe pre-calibrated, is used to measure the conductivity of fluid as thefluids exit, for example, a turbine compressor being washed. High levelsof contaminants in the fluid decrease the fluid's conductivity.Similarly, low levels of contaminants provide for higher fluidconductivity levels.

Coupled to the conductivity sensor 310 is the transmitter 320. Thetransmitter 320 receives conductivity measurements from the conductivitysensor 310 and transmits them to a computer system (not shown) forprocessing.

In operation, the conductivity sensor 310 and the transmitter 320 may bestrategically disposed within a wash system so as to interact with usedwash fluid as the fluid exits the machinery being washed. In anexemplary embodiment, the sensor 310 and transmitter may be mountedwithin a discharge drain line of the gas turbine compressor. In such animplementation, the conductivity sensor 310 and the transmitter 320 maybe mounted via a screw insertion, a retractable insertion with a ballvalve, a flow-through design, or by other appropriate means.

During a washing operation, used wash fluid containing detergents,contaminants, fouling, etc. exits the turbine compressor through thedrain line and encounters the conductivity sensor 310. The sensor 310measures the electric conductivity of the used fluid and provides itsmeasurements to the transmitter 320. The transmitter 320, which may bein communication with a computing system, provides the sensor's 310measurements to the computing system. The computing system in turncompares the measurements to either pre-loaded conductivity data or topre-set conditions to determine the status of the washing/rinsingoperation. The closer the conductivity measurements are to thepre-loaded data or pre-set conditions, the closer the washing/rinsingoperation will be to being completed. Exemplary pre-set conditions mayinclude comparing measured conductivity levels to values indicative offluid contaminant levels, detergent levels, etc.

Once the measured conductivity levels are within an acceptable range, anoperator may terminate the operation, thereby saving time, fluid, andmoney. Optionally, the computing system may be configured to storepreviously “accepted” measurements for use during future washing/rinsingoperations.

FIG. 4 illustrates a cross-sectional view of a typical gas turbine inlet400 with rotor shaft 410, combustion zone 413, turbine blades 414, waterwash nozzles 415, compressor 411,412, and compressor discharge drain416. The basic gas turbine operation draws ambient air from region Athrough an inlet filter system 402, 403, and 404. The overall inlet is acontinuous air tight structure 401. Filtered air moves through the inletregions B, C, D and is compressed by the increased velocity and flowcaused by the draw from the compressor 411, 412. The air then enters thecompressor 411, 412 and is further compressed. At the end of thecompressor 411, 412 is a compressor discharge casing region and drain416, which may be equipped with the rinse cycle sensor apparatus 300described with reference to FIG. 3. Measurements taken from thisapparatus 300 during the wash process are transmitted to a computersystem (not shown) to determine the extent of contaminants being removedfrom the compressor 411, 412. Once the conductivity measurements reachpredetermined levels, the system operator (not shown) can be assuredthat the final wash rinse is free of solids, indicating removal ofdetergent and contaminates from the compressor 411, 412. Thisinformation may be utilized by the operator to terminate the wash/rinseoperation. In addition, the data collected during such a wash/rinseoperation may be logged and stored to allow correlation with othertracked wash parameters.

Although specific embodiments have been shown and described herein forpurposes of illustration and exemplification, it is understood by thoseof ordinary skill in the art that the specific embodiments shown anddescribed may be substituted for a wide variety of alternative and/orequivalent implementations without departing from the scope of thepresent invention. This disclosure is intended to cover any adaptationsor variations of the embodiments discussed herein.

1. A washing system comprising: a wash delivery system; a fluid supplycoupled to an input of the wash delivery system; a fluid delivery linecoupled at one end to an output of the wash delivery system; a washapparatus coupled at an opposite end of the fluid delivery line forreceiving wash fluid via the fluid delivery line and injecting the washfluid into a object desired to be washed; and a purge drain valvespliced into the fluid delivery line between the wash delivery systemand the wash apparatus, the purge drain valve having a drain end;wherein, during a washing operation, the purge drain valve is operableto permit wash fluid to flow free between the wash delivery system andthe wash apparatus; and wherein during a purging operation, the drainvalve is operable to prevent wash fluid from entering the wash apparatusand diverts the wash fluid to the drain end.
 2. The washing system ofclaim 1, further comprising a control input coupled to an input of thewash delivery system for transmitting input control signals to the washdelivery system.
 3. The washing system of claim 2, further comprising acontrol output coupled between an output of the wash delivery system andan input of the purge drain valve for transmitting output controlsignals to the drain valve, the output control signals operable toactuate the purge drain valve.
 4. The washing system of claim 3, whereinthe wash delivery system generates the output control signals operableto actuate the purge drain valve.
 5. The washing system of claim 1,further comprising a power supply coupled to an input of the washdelivery system to provide power to the wash delivery system.
 6. Thewashing system of claim 1, wherein the wash delivery system includes oneor more containers for storing fluids for use in the washing operation.7. The washing system of claim 6, wherein the wash delivery systemprocesses the fluids being stored therein for the washing operation. 8.The washing system of claim 1, further comprising a drain collector tocollect purged fluids diverted to the drain end.
 9. The washing systemof claim 1, further comprising a supply valve coupled to the fluidsupply, wherein the supply valve is operably opened and closed by thewash delivery system.
 10. The washing system of claim 1, wherein duringthe purging operation, pressurized air flows between the wash deliverysystem to the purge drain valve.
 11. The washing system of claim 1,wherein the wash apparatus comprises a water wash manifold and/or anozzle assembly.
 12. A rinse cycle sensor apparatus to indicate to anoperator completion of a washing operation, the apparatus comprising: aconductivity sensor that measures the conductivity of fluid as the fluidexits a device being washed; and a transmitter coupled to theconductivity sensor to receive conductivity measurements from theconductivity sensor and to transmit the conductivity measurements to acomputer system for processing, wherein the conductivity sensor and thetransmitter are disposed within a wash system to obtain conductivitymeasurements of wash fluid as the wash fluid exits the device beingwashed.
 13. The apparatus of claim 12, wherein the conductivity sensorcomprises a pre-calibrated conductivity sensor.
 14. The apparatus ofclaim 12, wherein the conductivity sensor and the transmitter aremounted within a drain line of the compressor discharge case drain byone of (i) a screw insertion; (ii) a retractable insertion with a ballvalve; and (iii) a flow-through design.
 15. The apparatus of claim 12,wherein the wash fluid comprises used wash fluid containing detergents,contaminants, and fouling.
 16. The apparatus of claim 15, wherein theconductivity measurements indicate a level of contamination in the washfluid.
 17. A method for completing a rinse cycle of a device, the methodcomprising: providing a rinse cycle sensor apparatus, comprising: aconductivity sensor that measures the conductivity of fluid as the fluidexits the device being washed; and a transmitter coupled to theconductivity sensor to receive conductivity measurements from theconductivity sensor and to transmit the conductivity measurements to acomputer system for processing; attaching the rinse cycle sensorapparatus within a drain line of the device being washed to obtain theconductivity measurements of fluid as the fluid exits the device beingwashed; receiving the conductivity measurements of the exited fluid; andanalyzing the conductivity measurements of the exited fluid againstpreset conditions.
 18. The method of claim 17, wherein analyzing theconductivity measurements of the exited fluid against preset conditionscomprises comparing the conductivity measurements against presetconditions stored in a knowledge base.
 19. The method of claim 17,wherein the preset conditions indicate at least one of (i) excessdetergent in the fluid; (ii) excess contaminates in the fluid; (iii)minimal detergent in the fluid; and (iv) minimal contaminates in thefluid.
 20. The method of claim 17, wherein the preset conditions areelectronically accessible.
 21. The method of claim 18, furthercomprising completing the rinse cycle if the analysis of theconductivity measurements satisfies the preset conditions.